U.S. patent application number 16/816629 was filed with the patent office on 2020-10-08 for incline elevator and modular deck system and methods for the assembly, use and shipping thereof.
The applicant listed for this patent is John Sund. Invention is credited to John Sund.
Application Number | 20200317473 16/816629 |
Document ID | / |
Family ID | 1000004930655 |
Filed Date | 2020-10-08 |
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United States Patent
Application |
20200317473 |
Kind Code |
A1 |
Sund; John |
October 8, 2020 |
INCLINE ELEVATOR AND MODULAR DECK SYSTEM AND METHODS FOR THE
ASSEMBLY, USE AND SHIPPING THEREOF
Abstract
An incline elevator system includes a pair of laterally spaced
rails and a carriage configured with restraining members extending
laterally beneath a bottom surface of the rail in a vertically
spaced relationship therewith. A rail kit, together with methods of
assembling the elevator system, is also provided. A modular deck
system includes a plurality of box treads arranged in an array and
a plurality of stanchions supporting the array. Methods of
assembling the array of box treads are also provided.
Inventors: |
Sund; John; (Columbiaville,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sund; John |
Columbiaville |
MI |
US |
|
|
Family ID: |
1000004930655 |
Appl. No.: |
16/816629 |
Filed: |
March 12, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62819212 |
Mar 15, 2019 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B66B 19/00 20130101;
B66B 7/02 20130101; B66B 9/06 20130101 |
International
Class: |
B66B 9/06 20060101
B66B009/06; B66B 19/00 20060101 B66B019/00; B66B 7/02 20060101
B66B007/02 |
Claims
1. An incline elevator system comprising: a pair of laterally
spaced rails, wherein each of the rails extends longitudinally and
comprises a head having an upper bearing surface and a support web
extending downwardly from the head and comprising inner and outer
surfaces, and wherein the head comprises a bottom surface spaced
below the upper bearing surface and positioned laterally inwardly
from the inner surface of the support web; a carriage comprising: a
laterally extending cross member; a pair of longitudinally
extending and laterally spaced beams connected to the cross member,
each of the beams comprising a restraining member extending
laterally beneath the bottom surface of the rail in a vertically
spaced relationship therewith, wherein each of the restraining
members is spaced laterally inwardly from the inner surface of a
corresponding one of the rails; and at least one roller rotatably
coupled to each of the beams and engaged with the upper bearing
surface of one of the rails.
2. The incline elevator system of claim 1 wherein each of the beams
comprises a top wall overlying the at least one roller and inner
and outer side walls extending downwardly from the top wall,
wherein the inner wall extends downwardly below the bottom surface
of the head, and wherein the restraining member comprises a flange
extending laterally outwardly from the inner wall toward the inner
surface of the support web.
3. The incline elevator system of claim 1 further comprising a
plurality of laterally extending spreaders extending between and
connected to the inner surface of the support webs.
4. The incline elevator system of claim 3 further comprising a
plurality of stanchions coupled to the plurality of spreaders,
wherein the stanchions are configured to be anchored in the
ground.
5. The incline elevator system of claim 4 wherein the plurality of
stanchions comprises at least a pair of stanchions coupled to each
of the spreaders.
6. The incline elevator system of claim 5 wherein the spreaders are
connected to each of the stanchions with one or more
U-brackets.
7. The incline elevator system of claim 1 wherein the rails and
beams are inclined relative to a horizontal plane.
8. The incline elevator system of claim 7 further comprising a
carriage body coupled to at least one of the cross member and
beams, wherein the carriage body comprises a horizontal seating
surface.
9. The incline elevator system of claim 1 wherein the head
comprises an upper web, an inner side wall extending downwardly
from the upper web and a flange extending outwardly from the inner
side wall and defining the bottom surface.
10. The incline elevator of claim 9 wherein the inner side wall of
the head is spaced laterally inwardly from the inner surface of the
support web, and wherein the upper web and the flange define a
space therebetween.
11. A method of assembling an incline elevator system comprising:
installing a pair of rails in a laterally spaced relationship,
wherein each of the rails extends longitudinally and comprises a
head having an upper bearing surface and a support web extending
downwardly from the head and comprising inner and outer surfaces,
wherein the head comprises a bottom surface spaced below the upper
bearing surface and positioned laterally inwardly from the inner
surface of the support web, the rails each having a terminal end;
moving a carriage longitudinally relative to the terminal end of
the rails and engaging the upper bearing surface of the rails with
rollers while moving a restraining member beneath the bottom
surface of each of the rails in a vertically spaced relationship
therewith, wherein each of the restraining members is spaced
laterally inwardly from the inner surface of a corresponding one of
the rails.
12. The method of claim 11 wherein the carriage comprises a
laterally extending cross member connected to a pair of
longitudinally extending and laterally spaced beams, wherein each
of the beams includes one of the restraining members, and wherein
the rollers comprise at least one roller rotatably coupled to each
of the beams.
13. The method of claim 12 wherein each of the beams comprises a
top wall overlying the at least one roller and inner and outer side
walls extending downwardly from the top wall, wherein the inner
wall extends downwardly below the bottom surface of the head, and
wherein the restraining member comprises a flange extending
laterally outwardly from the inner wall toward the inner surface of
the support web.
14. The method of claim 11 further comprising a plurality of
laterally extending spreaders extending between and connected to
the inner surface of the support webs.
15. The method of claim 14 further comprising driving a plurality
of stanchions into the ground and coupling the plurality of
spreaders to the plurality of stanchions.
16. The method of claim 15 wherein coupling the plurality of
spreaders comprises connecting each of the spreaders to each of the
stanchions with a U-bracket.
17. The method of claim 11 wherein the rails and beams are inclined
relative to a horizontal plane.
18. The method of claim 17 further comprising supporting a carriage
body with the at least one of the cross member and beams, wherein
the carriage body comprises a horizontal seating surface.
19. The method of claim 11 wherein the head comprises an upper web,
an inner side wall extending downwardly from the upper web and a
flange extending outwardly from the inner side wall and defining
the bottom surface.
20. The method of claim 19 wherein the inner side wall of the head
is spaced laterally inwardly from the inner surface of the support
web, and wherein the upper web and the flange define a space
therebetween.
21-40. (canceled)
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/819,212, filed Mar. 15, 2019 and entitled
Incline Elevator and Modular Deck System and Methods for the
Assembly, Use and Shipping Thereof, the entire disclosure of which
is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present application relates generally to an incline
elevator and modular deck system, together with methods for the
use, assembly and shipping thereof.
BACKGROUND
[0003] Bluffs are formed along the shores of various waterways,
including oceans, lakes and rivers, or in various mountainous or
hilly areas. Often, it is desirable to access a bottom of the bluff
or hill from a location higher up on the bluff or hill, for example
to provide access to and/or from a lodging or parking area. While
various stair systems may be assembled along such bluffs or hills,
traversing such stairs may not be possible for various persons,
including those with disabilities. Likewise, repeated trips up and
down such stair systems, or trips involving cumbersome loads, may
be not be feasible even for able-bodied individuals.
[0004] To solve this problem, various incline elevator systems, or
furnicular railways, may be installed on the bluff or hill to
provide transportation between upper and lower locations by way of
a carriage. The installation of such systems may be problematic,
however, when located on relatively steep inclined surfaces, or
where the ground surface is soft and susceptible to shifting, for
example along sandy bluffs.
[0005] In addition, and due to the gravity induced descent
encountered if various stop systems fail, it is important for such
systems to ensure that the carriage stays on the tracks.
Accordingly, there is a need for tamper proof systems that preclude
derailment.
[0006] As can be appreciated, worksites where such incline elevator
systems are installed may often be located at remote locations. As
such, it may be difficult and expensive to ship/transport the
appropriate building materials to the worksite.
[0007] In addition, it is often desirable to provide upper and
lower deck systems providing access to such incline elevators.
Often, such decks must be custom built, with underlying support
beams, joists and/or truss structures. Such construction can be
expensive and time consuming. In addition, such systems are not
easily reconfigured or repaired, and are typically made of
materials, such as wood, that wear over time under adverse weather
conditions. Moreover, the surface of such systems may be slippery
when wet, and cause erosion due to water run-off patterns created
by the deck configuration.
SUMMARY
[0008] The present invention is defined by the following claims,
and nothing in this section should be considered to be a limitation
on those claims.
[0009] In one aspect, one embodiment of an incline elevator system
includes a pair of laterally spaced rails. Each of the rails
extends longitudinally and includes a head having an upper bearing
surface and a support web extending downwardly from the head. The
support web has inner and outer surfaces, while the head includes a
bottom surface spaced below the upper bearing surface and
positioned laterally inwardly from the inner surface of the support
web. A carriage includes a laterally extending cross member and a
pair of longitudinally extending and laterally spaced beams
connected to the cross member. Each of the beams includes a
restraining member extending laterally beneath the bottom surface
of the rail in a vertically spaced relationship therewith. Each of
the restraining members is spaced laterally inwardly from the inner
surface of a corresponding one of the rails. At least one roller is
rotatably coupled to each of the beams and engaged with the upper
bearing surface of one of the rails.
[0010] In another aspect, one embodiment of a method of assembling
an incline elevator system includes installing a pair of rails in a
laterally spaced relationship, with the rails each having a
terminal end. The method further includes moving a carriage
longitudinally relative to the terminal end of the rails and
engaging an upper bearing surface of the rails with rollers while
moving a restraining member beneath a bottom surface of each of the
rails in a vertically spaced relationship therewith. Each of the
restraining members is spaced laterally inwardly from an inner
surface of a corresponding one of the rails.
[0011] In another aspect, one embodiment of a modular deck system
includes a plurality of box treads, each having an upper wall,
opposite side walls extending downwardly from the upper wall and
opposite end walls extending downwardly from the upper wall. The
plurality of box treads are arranged in an array, including at
least some box treads arranged in a side-to-side relationship,
and/or at least some box treads arranged in an end-to-end
relationship. Abutting side walls of adjacent box treads are
coupled with fasteners, and abutting end walls of adjacent box
treads are coupled with fasteners. A plurality of stanchions
support the array. Each of the stanchions is coupled directly to at
least one end wall or at least one side wall of one of the
plurality of box treads. The stanchions are the only structure
supporting the array of box treads on the ground.
[0012] In one embodiment, the upper wall may be configured with a
plurality of openings arranged in an array of elongated openings.
In addition, the upper wall may be configured with a plurality of
raised dimples arranged between the openings.
[0013] In yet another aspect, one embodiment of a method of
assembling a modular deck system includes arranging a plurality of
box treads in an array, wherein at least some of the box treads are
arranged end-to-end and at least some of the box treads are
arranged side-to-side, coupling abutting side walls of adjacent box
treads with fasteners, coupling abutting end walls of adjacent box
treads with fasteners, and supporting the array of box treads with
a plurality of stanchions by coupling each of the stanchions
directly to at least one end wall or at least one side wall of one
of the plurality of box treads. In one embodiment, the stanchions
are the only structure supporting the array of box treads.
[0014] A kit for assembling a rail system includes a plurality of
rails each having a length, a height defined between an upper
surface of a head and a bottom surface of a foot and a width
defined between opposite sides of the head. The rails are stacked
in a plurality of columns, each of the columns including a
plurality of nested pairs of rails. Each of the nested pairs of
rails includes a head of a first rail engaging a foot of a second
rail and a foot of the first rail engaging a head of the second
rail.
[0015] The various embodiments of the incline elevator system,
modular deck system, kit for assembling a rail system and various
methods for assembly and/or use, provide significant advantages
over other incline elevator and/or deck systems. For example and
without limitation, the restraining members ensure the carriage
remains engaged with the rails, thereby avoiding derailment of the
carriage from the rails. Because the restraining members are
positioned inboard of the rails, and are integrally formed with the
beams supporting the rollers, the system is tamper resistant, and
the restraining members may not be removed or otherwise disengaged
from the rails except by moving the carriage out of engagement at
one of the terminal ends of the rail system.
[0016] The modular deck system also provides significant
advantages. In particular, the box treads can be easily laid out in
a desired array and connected together to provide a rigid,
self-supporting structure that avoids the need for underlying
joists and beams. In addition, the supporting stanchions can be
driven into the ground at the desired locations and thereafter
attached to the box treads, again foregoing the need for any
underlying support structure. The system can be quickly and easily
reconfigured simply by disconnecting adjacent box treads and
installing new treads, or arranging the treads in a different
array.
[0017] The configuration of the upper wall of the treads also
provides various advantages. For example and without limitation,
the configuration of the openings, including the shape, size and/or
pattern thereof, allows for water run off while minimizing any
erosion damage beneath the deck. The water run-off, combined with
the raised dimples and a polyurea surface coating, provides an
ideal non-slip surface suitable for use in all weather
conditions.
[0018] The kit also provides significant advantages. For example,
approximately 400 feet of rail may be shipped on a single pallet
having an overall footprint of 1.times.4.times.8 feet.
[0019] The foregoing paragraphs have been provided by way of
general introduction, and are not intended to limit the scope of
the claims presented below. The various preferred embodiments,
together with further advantages, will be best understood by
reference to the following detailed description taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIGS. 1A and B are views of an incline elevator system with
upper and lower modular deck systems.
[0021] FIG. 2 is a top view of the upper modular deck system shown
in FIG. 1.
[0022] FIG. 3 is a side view of the lower modular deck system
supported by stanchions.
[0023] FIG. 4 is a perspective view of a carriage
understructure.
[0024] FIG. 5 is a front view of the carriage understructure
positioned on a pair of rails supported by stanchions.
[0025] FIG. 6 is a side view of a rail section.
[0026] FIG. 7 is a side view of a rail system kit.
[0027] FIG. 8 is an end view of the rail system kit shown in FIG.
7.
[0028] FIG. 9A is a top view of one exemplary modular deck
array.
[0029] FIG. 9B is a side view of the modular deck array shown in
FIG. 9A.
[0030] FIG. 10A is a top view of a modular box tread.
[0031] FIG. 10B is an end view of the modular box tread taken along
line 10B-10B of FIG. 10A.
[0032] FIG. 10C is a side view of the modular box tread shown in
FIG. 10A.
[0033] FIG. 10D is an enlarged view of a dimple formed on the upper
surface of the box tread.
[0034] FIG. 11 is a perspective view of a spreader.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0035] It should be understood that the term "plurality," as used
herein, means two or more. The term "longitudinal," as used herein
means of or relating to a length or lengthwise direction 2, for
example a direction running along the length of a rail 6, beam 8 or
modular box tread 10. The term "lateral," as used herein, means
situated on, directed toward or running in a side-to-side direction
4, including for example between adjacent and parallel rails.
[0036] The term "coupled" means connected to or engaged with,
whether directly or indirectly, for example with an intervening
member, and does not require the engagement to be fixed or
permanent, although it may be fixed or permanent. The terms
"first," "second," and so on, as used herein are not meant to be
assigned to a particular component so designated, but rather are
simply referring to such components in the numerical order as
addressed, meaning that a component designated as "first" may later
be a "second" such component, depending on the order in which it is
referred. It should also be understood that designation of "first"
and "second" does not necessarily mean that the two components or
values so designated are different, meaning for example a first
direction may be the same as a second direction, with each simply
being applicable to different components. The terms "upper,"
"lower," "rear," "front," "side," "inner," "outer," "vertical,"
"horizontal," "right," "left," and variations or derivatives
thereof, refer to the orientations as shown in the Figures from the
perspective of a user or installer standing on or next to the
feature being described. The term "transverse" means non-parallel.
The term "outwardly" refers to a direction 12 facing away from a
centralized location, for example a centerline 16 between a pair of
rails (see FIG. 5). Conversely, the term "inwardly" refers to a
direction 14 facing toward the centralized or interior location
(e.g., centerline 16).
Incline Elevator System
Rails:
[0037] Referring to FIGS. 1A-5, an incline elevator system 18 is
situated on an inclined surface 20, such as a bluff or hill. In
various embodiments, the inclined surface 20 of the bluff or hill
may have a maximum slope of 45 degrees. A plurality of stanchions
22 are embedded in the ground at predetermine longitudinal
locations along the inclined surface 20, with the stanchions being
maintained in a substantially vertical orientation. In one
embodiment, pairs of laterally spaced stanchions 22 are spaced
longitudinally along the slope of the inclined surface, for example
at four foot intervals. It should be understood that in other
embodiments, a single stanchion, or more than two stanchions, may
be embedded at a predetermined longitudinal location. In one
embodiment, the stanchion 22 is a tubular post, which has a cap 24
secured to an upper end thereof to prevent water intrusion. The
stanchions may be embedded directly in the ground. In other
embodiments, the stanchions may be embedded in a concrete pillar.
The stanchions are preferably made of metal, for example and
without limitation galvanized steel.
[0038] Referring to FIGS. 1, 5 and 11, a laterally extending
spreader 26 is secured to each of the pairs of stanchions at each
longitudinal location. The spreader 26 is maintained in a
horizontal orientation. In one embodiment, the spreader 26 is
configured with a laterally extending rod or tube 28 and a pair of
laterally spaced end plates 30 secured to the opposite ends of the
tube 28, for example by welding, as shown in FIGS. 5 and 11. In one
embodiment, the tube 28 is coupled to the plates 30 off center,
such that a greater portions of the plates 30 extend upwardly from
the tube 28. Each plate 30 includes a plurality of fastener
openings 32, shown for example as two vertically spaced rows of
four openings 32. The spreader 26, including the tube 28 and plates
30, is preferably made of a rigid material, such as metal,
including example and without limitation galvanized steel.
[0039] The spreader 26 may be connected to the one or more
stanchions with one or more brackets, for example and without
limitation two pairs of U-brackets 34. One pair of horizontally
spaced U-brackets 34 (each in a vertical orientation) surrounds the
rod 26, which is clamped between the U-brackets 34 and a back plate
36. Ends of the U-brackets are threaded and engaged with nuts 38. A
second pair of vertically spaced U-brackets 34 (each in a
horizontal orientation) surrounds the stanchion 22 and are coupled
to the same back plate 36, again with ends of the U-brackets
engaged with nuts 38. In this way, the stanchions 22 are coupled to
the spreader 26, with the back plate 36 disposed therebetween.
[0040] Referring to FIGS. 4-6, pairs of rails 6 are coupled to the
spreader end plates 30. A plurality of rails 66 are arranged
end-to-end in the longitudinal direction 4 along the overall length
of the railway to form a railway. The rails 6 are made of metal,
for example 11 Gauge galvanized steel. The end plate 30 of one
spreader 26 overlaps and bridges between the abutting ends of
longitudinally adjacent rails 6. The spreader plate 30 aligns and
secures the abutting rails and thereby ensures that the upper
bearing surfaces of the rails are contiguous. One of the spreaders
26 may also be secured to an intermediate location of the each rail
6. As shown in FIG. 6, the rails 6 are provided with a pair of four
fastener openings 40 at an intermediate location that match the
opening pattern in the spreader end plates, and has two pairs of
vertically spaced openings at either a distance D1 or D2, for
example at 1 inch and 3 inches. As such, the openings 32 in the
spreader end plate may be aligned with the openings 40 at D1 on one
rail and with the openings at D2 on an abutting, adjacent rail.
Each end plate 30 is abutted against and secured to an inner
surface 44 of a support web 42, for example with four bolts 46
engaged with nuts. The support web 42 has an outer surface 48. The
spreader end plate 30 is nested between a head 50 of the rail
arranged at the upper end of the support web and a foot 52 of the
rail arranged at a lower end of the support web. The foot 52 may be
configured as an inwardly or laterally extending flange. In other
embodiments, the foot may be simply be configured as a terminal
bottom edge of the support web 42. The head and foot define a
channel 54 in which the spread end plate 30 is disposed. The
modified C-channel cross section of the rail 6 provides increased
bending strength and rigidity, allowing the rails to support and
carry the load of the carriage. The head 50 includes an upper web
56, an inner side wall 58 extending downwardly from the upper web
and a flange 60 extending outwardly from the inner side wall and
defining a bottom surface 62 of the head. The inner side wall 58 of
the head is spaced laterally inwardly from the inner surface 44 of
the support web. The upper web 56 and the flange 60 define a space
therebetween. In one embodiment, the flange 60 extends outwardly to
an approximate centerline of the head, while the foot flange 52
extends inwardly to the same approximate centerline. The upper web
of the head defines an upper bearing surface 66. As shown the
support web 42 defines the outermost surface 48 of the rail.
Rail Kit:
[0041] Referring to FIGS. 6-8, a rail kit 68 for assembling a rail
system includes a plurality of rails 6. The rails are stacked such
that a large volume of rails may be easily shipped in a single
standard shipping unit. For example in one embodiment, 400 feet of
rails 6 may be shipped in a single shipping unit. Such a unit, or
kit 68, would allow for a 200 foot installation (with two lines of
laterally spaced rails), which encompasses the majority of
residential and commercial incline elevator systems. The compact
nature of the shipping unit, or kit 68, is accomplished by the
unique shape and nesting arrangement of the rails. In particular,
each of the rails has a length L1, a height H1 defined between the
upper bearing surface of the head and a bottom surface of the foot,
and a width W1 defined between opposite sides of the head (or
between the outer surface 48 of the support web and the inner
surface 70 of the inner side wall 58 of the head). It should be
understood that a bottom surface 72 of the foot 52 may be defined
as the bottom edge of the support web if the flange is omitted. In
one embodiment, the rails 6 each have an overall length (L1)
slightly less than 8 feet, for example 7 feet, 117/8 inches. The
height (H1) of each rail 6 is slightly less than 9 inches, for
example 8.50 inches, while the width (W1) is slightly less than 2
inches, for example 1.94 inches.
[0042] In one embodiment, the rails 6 are stacked in a plurality of
columns 74, with each of the columns including a plurality of
nested pairs 76 of rails. Each nested pair of rails includes a head
50 of a first rail engaging a foot 52 of a second rail and a foot
52 of the first rail engaging a head 50 of the second rail. As
disclosed herein, the support web 42 of each rail is contiguous
with one of the sides of the head and extends between the head and
the foot. As noted, the support web 42 has an outer surface 48 and
an inner surface 44. The outer surface 48 of a lower rail of a
first nested pair 76 is supported by an outer surface 48 of an
upper rail of a second nested pair 76 positioned adjacent to and
immediately below the first nested pair.
[0043] In one embodiment, the kit 68 includes five columns 74 of
rails 6, with each column having five nested pairs 76 of rails. In
this embodiment, the kit 68 has an overall length (L1) of eight
feet or less, an overall width (W2) of four feet or less (e.g., 3
feet 65/8 inches) and an overall height (H2) of one foot or less
(e.g., 101/4 inches). As such, the kit 68 fits within the footprint
of a standard skid 78 or pallet having a 4.times.8 feet
dimension.
Carriage:
[0044] Referring to FIGS. 1A, B, 4 and 5, a carriage 80 includes a
carriage body 82 coupled to and supported by a carriage
understructure 84. The carriage body includes in one embodiment a
floor 88, a seating surface 90 and a peripheral railing 86. The
floor and seating surface may be maintained along a horizontal
plane, while the understructure 84 is coupled thereto at an angle
matching the angle of the underlying rails 6, for example with
posts, braces or other structural members.
[0045] The carriage understructure 84 includes a plurality of
laterally extending cross members 92 and longitudinally extending
beams 102. The cross members have aligned apertures 94 formed
therethrough along a centerline of cross members between the rails.
A drive system, including for example a yoke 96, passes through the
openings, and is engaged with the understructure. A chain or belt
drive 98 is coupled to the yoke 96 and may be actuated to pull the
carriage upwardly along the rails, or to permit a controlled
descent of the carriage along the rails between upper and lower
positions. A motor 100 is coupled to and actuates the drive 98.
[0046] A pair of parallel beams 102 are coupled to opposite ends of
the cross members 92, for example by welding or with fasteners.
Each beam is made of steel, for example galvanized steel. Each beam
102 is configured with a top wall 104 or web and inner and outer
side walls 106, 108 or webs extending downwardly from the top wall.
The inner wall 106 extends downwardly below the bottom surface 62
of the head 50. A restraining member 110, configured as a flange,
extends laterally outwardly from the inner wall toward the inner
surface 44 of the support web. The restraining member 110 extends
laterally beneath the bottom surface 62 of head of the rail in a
vertically spaced relationship therewith, defining a gap G1. The
restraining members 110 of the laterally spaced beams are spaced
laterally inwardly from the inner surfaces 44 of the rails.
[0047] At least one roller 112 (e.g., wheel), and preferably a pair
of longitudinally spaced rollers, are rotatably coupled to each of
the beams 8 and engaged with the upper bearing surface 66 of one of
the rails. The roller 112 has laterally spaced circumferential lips
or rims 114 that extend along opposite sides of the head 50, with
the rims 114 and a bearing surface 116 defining a channel 118 that
receives the bearing surface 66 of the rail head 50. The channel
118, or rims 114, has a depth greater than the dimension of the gap
G1, such that the restraining member 110 will engage the bottom
surface 62 of the head before the rim 114 can ride up over the
bearing surface of the head. The head 50 of the rail is vertically
captured between the rollers 112 and the restraining flange 110,
which ensures that the rollers maintain engagement with the rails.
The head 50 is also laterally captured between the rims 114. The
rollers are secured to the beams with an axle 120 extending through
the inner and outer walls, with a bolt head 122 engaging the outer
wall and a nut 124 engaging the inner wall, with various washers
installed on the bolt as deemed necessary. The rollers may be made
of hard plastic, metal, rubber or other suitable materials.
Assembly:
[0048] A method of assembling the inclined elevator system includes
installing a plurality of stanchions 22 at predetermined locations
along the slope of the inclined surface 20. The stanchions 22 may
be installed by driving one end into the ground a sufficient
distance to anchor the stanchion. Spreaders 26 are coupled to the
stanchions with brackets 34, 36. Pairs of rails 6 are connected to
the spreaders 26 in a laterally spaced relationship, with a
spreader bridging between and securing abutting ends of
longitudinally adjacent rails. Each of the rails 6 extends in the
longitudinal direction 2 along the inclined surface 20. The
combination of each of the two laterally spaced rail systems, or
the uppermost and lowermost rail on each side, define upper and
lower terminal ends 126, 128 of the rail system.
[0049] The carriage 80 is aligned with one of the upper or lower
terminal ends 126, 128, and is moved longitudinally, or in the
longitudinal direction 2, relative to one of the terminal ends 126,
128 such that the rollers 112 engage the upper bearing surface 66
of the rails while the restraining members are 110 moved beneath
the bottom surface 62 of each of the rails 6 in a vertically spaced
relationship therewith. Each of the restraining members 110 is
spaced laterally inwardly from the inner surface 44 of a
corresponding one of the rails. In this way, the carriage is
moveably installed and supported on the rail system. The carriage
80 cannot be removed from the rails except to move it
longitudinally away from the upper or lower terminal end and off
the rails. In other words, the restraining members 110, which are
located between the rails and cannot be tampered with or removed,
ensures that the carriage is safely secured to the rails and cannot
be dislodged therefrom in either the vertical or lateral direction.
In operation, the restraining member 110 engages the bottom surface
62 of the head if the roller is somehow caused to lift upwardly
from the rail, and also engages the inner wall or surface of the
rail head and/or support web if laterally displaced, with the
engagement preventing the carriage 80 from derailing from the rails
6.
Modular Deck System
[0050] Referring to FIGS. 1A-3 and 9A-12, a modular deck system 150
includes a plurality of box treads 152. It should be understood
that the modular deck system may be installed at any desired
location, and is not required to be used with an incline elevator
system, although it may be used with such systems, for example to
provide an upper and lower ingress/egress for the inclined elevator
system while also providing a walkway from the inclined elevator
system to a waterfront or other attraction. Rather, the modular
deck system is a stand-alone system, and may be installed adjacent
a building structure, or by itself, for example as a dock or pier,
wherever it is desired to provide a platform.
[0051] Each box tread includes an upper wall 154, defining a
platform or deck/tread surface 160, opposite side walls 156
extending downwardly from the upper wall and opposite end walls 158
extending downwardly from the upper wall. The upper wall, side
walls and end walls may be formed integrally, with each of the side
walls and end walls folded along fold lines defined side and end
edges 162, 164 of the box tread. A bottom edge of each of each of
the side walls includes a flange 166 extending laterally inwardly
to stiffen the side walls. The upper wall, side walls and end walls
define a cavity. The height (H3) of the side walls, and end walls,
is sufficient to ensure that the box tread has sufficient strength
and resistance to bending, wherein the box tread is self-supported,
and does not require additional underlying support (e.g., joists or
beams). In one embodiment the height (H3) of the side walls and end
walls is between 3 and 6 inches, and about 4 inches in one
embodiment, with the flange 166 having a length of about 1 inch. In
one embodiment, the box tread is made of 12 GA A-60 galvennealed
steel. Depending on the thickness and type of material, the height
of the treads may be altered without sacrificing the strength and
resistance to deformation. Each box tread 152 is covered with a
coating 168, for example a polyurethane and polyuria blend, which
provides additional protection against the elements and contributes
to a non-slip surface. In one embodiment, the coating is a 0.035
inch Vortex.TM. liner.
[0052] The upper wall 154, or tread surface, is configured with a
plurality of openings 170, configured as elongate obround openings
in one embodiment. In one preferred embodiment, the openings have a
0.234.times.1.190 OBR dimension. The openings may be arranged in
longitudinally extending and laterally spaced rows 172. Adjacent
rows may be staggered, such that an opening in one row is laterally
spaced from a bridge portion 174 between two openings in an
adjacent row, or with the matrix of openings forming diagonal
columns of openings extending between the opposite side edges. In
one embodiment, the overall length (L2) of the tread is
approximately 48 inches (e.g. 4 feet). In various alternative
embodiments, the overall length of the tread may be 1, 2, 3 or 5
feet. In an embodiment wherein L2 is 4 feet, five rows 172 of
openings (58 total) are arranged in the upper wall, with three rows
of 12 openings and 2 rows of 11 openings, with the centers of
adjacent openings in each row spaced apart at 4 inches. It should
be understood that the number of openings may be altered to
accommodate box treads having other longitudinal lengths. It should
be understood that openings having different shapes, dimensions,
spacing and frequency may also be suitable. The openings 170,
including the elongation, spacing and frequency thereof, ensures
that sufficient drainage is provided to allow for quick and
efficient water run-off, for example during a rain storm or if
splashed with waves. At the same time, the opening size, spacing
and frequency prevents concentrated run-offs that may cause erosion
in the ground surface below the deck, as may be experienced for
example by a traditional deck with planks spaced apart along the
lengths thereof.
[0053] The upper wall 154, or tread surface, is also configured
with a plurality of raised dimples 176, configured as dome shaped
protuberances. The uppermost surface of the dimples may extend a
distance H4 above the surface 160, with H4 being 0.080 inches in
one embodiment. The dimples may have a central through-opening 178,
or be closed. In one embodiment, the through opening 178 is 0.125
inches in diameter, while the overall dimple is circular in plan
view and has a diameter or width (W3) of 0.375 inches and a height
of 0.080 inches, with it being understood that other sizes and
shapes of the openings may be suitable. The dimples 176 may be
arranged in longitudinally extending and laterally spaced rows 180.
Adjacent rows may be staggered, such that a dimple 176 in one row
180 is laterally spaced from a bridge portion 182 between two
adjacent dimples in an adjacent row, or with the matrix of dimples
forming diagonal columns of dimples extending between the opposite
side edges. The angle of the diagonal columns of dimples is
different than the angle of the diagonal columns of openings. In
one embodiment, six rows 180 of dimples 176 (141 total) are
arranged in the upper wall, with two outermost rows of dimples
arranged between the outermost rows of openings and the side edges
162. Three rows of dimples 180 have 24 dimples, while the other
alternating rows 180 are configured with 23 dimples, with the
centers of adjacent dimples in each row spaced apart at 1 inch. It
should be understood that the number of dimples may be altered to
accommodate box treads having other longitudinal lengths. The
dimples 176, including the height (H3), width, spacing and
frequency thereof, ensure that a sufficient grip surface is
provided and exposed to the user. It should be understood that
dimples having different shapes, dimensions, spacing and frequency
may also be suitable.
[0054] As shown in FIGS. 9A and 10A, the openings 170 and raised
dimples 176 in combination define a pattern, with three dimples
defining a triangular space in which the opening 170 is
disposed.
[0055] Referring to FIG. 10B, the end walls 158 are configured with
a plurality of fastener holes 182, for example two laterally spaced
rows of two vertically spaced fasteners holes, each row having a 2
inch center spacing between holes and a 1 inch center to side edge
spacing, with each of the bottom holes having a 1 inch center to
bottom edge spacing.
[0056] Referring to FIG. 10C, the side walls 156 are configured
with a plurality of fastener holes 184, for example four rows of
longitudinally spaced fasteners holes spaced apart at 12 inch
intervals (and 6 inches between the end rows and end walls), with
each row having three equally, and vertically, spaced openings.
[0057] Referring to FIGS. 9A and B, a plurality of box treads 152
may be arranged in an array, with the plurality of box treads
arranged in side-to-side and end-to-end relationships. For example,
a row 186, 188, 190 of box treads may be connected to end-to-end,
with fasteners 194 secured through mating openings. Adjacent rows
may then be secured one to the other at 12 inch intervals with
fasteners 192 such that the openings 184 in the side walls are
aligned, with the adjacent rows being staggered or aligned. Shorter
box treads may be installed at the end of the run such that the
overall lengths of adjacent runs are the same. Abutting side walls
of adjacent box treads are coupled with fasteners, and abutting end
walls of adjacent box treads are coupled with fasteners. The box
treads may be coupled end-to-end to make any length, using any of
the different lengths of box treads. In addition, adjacent runs of
box treads may be bolted side-to-side in any position on 12 inch
centers to provide various configurations.
[0058] If a box tread 152 becomes damaged, the box treads may be
easily disassembled simply by removing the fasteners 192, 194, and
replacing the box tread 152. Likewise, if it is desired to
reconfigure the deck in a new array, the fasteners 192, 194 may be
removed, with the positioning of the box treads 152 altered to the
new configuration and reconnected. In some embodiments, the same
stanchions can be used to support multiple arrays. Alternatively,
the stanchions can be moved, and/or new stanchions installed, to
support a new array.
[0059] A plurality of stanchions 22 may be secured to the array
using U-brackets 34 in order to support the array above the ground.
The stanchions are driven into the ground and are arranged in a
predetermined pattern to be aligned with the side walls and/or end
walls of the array of box treads, wherein after each of the
stanchions is coupled directly to at least one end wall 158 or at
least one side wall 156. The stanchions are the only structure
supporting the array of box treads. In one embodiment, the
stanchions are configured the same as the stanchions used to
support the rail system. The connected box treads provide
sufficient bending strength between the stanchions such that no
additional underlying joist or beam structure is needed. A facing
202, configured as a thin plate, may be secured to the box treads
around the periphery of the array defining the modular deck. In
addition, a railing 200 may be secured to the modular deck, for
example to the facing and/or the end or side walls of various box
treads arranged around the perimeter of the array.
[0060] Although the present invention has been described with
reference to preferred embodiments, those skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention. As such, it
is intended that the foregoing detailed description be regarded as
illustrative rather than limiting and that it is the appended
claims, including all equivalents thereof, which are intended to
define the scope of the invention.
* * * * *